Hyundai Sonata: Front Driveshaft. Repair procedures - Revised - Driveshaft Assembly - Driveshaft and axleHyundai Sonata: Front Driveshaft. Repair procedures - Revised

Hyundai Sonata YF 2011-2014 Service Manual / Driveshaft and axle / Driveshaft Assembly / Front Driveshaft. Repair procedures - Revised

Replacement

1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from front hub .
Tightening torque:
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
3.
Remove the brake caliper mounting bolts , and then place the brake caliper assembly (B) with wire.
Tightening torque:
78.4 ~ 98.0 N.m (8.0 ~ 10.0 kgf.m, 57.8 ~ 72.3 lb-ft)

4.
Remove driveshaft nut (A) from the front hub under applying the break.
Tightening torque :
215.7 ~ 254.9 N.m (20.0 ~ 26.0 kgf.m, 159.1 ~ 188.0 lb-ft)

-
The washer (B) should be assembled with convex surface outward when installing the castle nut (A) and split pin (C).

5.
Loosen the front brake disc mount screw and then remove the front brake disc (A).
Tightening torque :
4.9 ~ 5.8 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)

6.
Remove the tie rod end ball joint (A) from the knuckle.
(1)
Remove the split pin (C).
(2)
Remove the castle nut (B).
Tightening torque:
34.3 ~ 44.0 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.5 lb-ft)

7.
Loosen the mount bolt and then remove the wheel speed sensor (A) from knuckle.
Tightening torque:
6.8 ~ 10.7 N.m (0.7 ~ 1.1 kgf.m, 5.0 ~ 7.9 lb-ft)

8.
Remove the lower arm (A) from the knuckle.
Tightening torque:
98.0 ~ 117.6 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.7 lb-ft)

9.
Disconnect the driveshaft (A) from the front hub assembly.
10.
Insert a pry bar (A) between the transaxle case and joint case, and separate the drive shaft (B) from the transaxle case.
11.
Install in the reverse order of removal.
•
Use a pry bar (A) being careful not to damage the transaxle and joint.
•
Do not insert the pry bar (A) too deep, as this may cause damage to the oil seal.
•
Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting in a torn boot or a damaged bearing.
•
Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
•
Support the driveshaft properly.
•
Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
12.
Check the alignment. (Refer to SSgroup 'Tires/Wheels - alingment')

Replacement

1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from front hub .
Tightening torque:
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
3.
Remove the brake caliper mounting bolts , and then place the brake caliper assembly (B) with wire.
Tightening torque:
78.4 ~ 98.0 N.m (8.0 ~ 10.0 kgf.m, 57.8 ~ 72.3 lb-ft)

4.
Remove driveshaft nut (A) from the front hub under applying the brake.
Tightening torque:
215.7 ~ 254.9 N.m (20.0 ~ 26.0 kgf.m, 159.1 ~ 188.0 lb-ft)

•
The front hub lock nut should be replaced with new ones.
•
After installation lock nut, stake the lock nut using a chisel and hammer as shown in the illustration below.

5.
Loosen the front brake disc mount screw and then remove the front brake disc (A).
Tightening torque :
4.9 ~ 5.8 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)

6.
Remove the tie rod end ball joint (A) from the knuckle.
(1)
Remove the split pin (C).
(2)
Remove the castle nut (B).
Tightening torque:
34.3 ~ 44.0 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.5 lb-ft)

7.
Loosen the mount bolt and then remove the wheel speed sensor (A) from knuckle.
Tightening torque:
6.8 ~ 10.7 N.m (0.7 ~ 1.1 kgf.m, 5.0 ~ 7.9 lb-ft)

8.
Remove the lower arm (A) from the knuckle.
Tightening torque:
98.0 ~ 117.6 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.7 lb-ft)

9.
Disconnect the driveshaft (A) from the front hub assembly.
10.
Insert a pry bar (A) between the transaxle case and joint case, and separate the drive shaft (B) from the transaxle case.
11.
Install in the reverse order of removal.
•
Use a pry bar (A) being careful not to damage the transaxle and joint.
•
Do not insert the pry bar (A) too deep, as this may cause damage to the oil seal.
•
Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting in a torn boot or a damaged bearing.
•
Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
•
Support the driveshaft properly.
•
Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
[T-GDI]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from front hub.
Tightening torque:
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
3.
Remove the brake caliper mounting bolts , and then place the brake caliper assembly (B) with wire.
Tightening torque:
78.4 ~ 98.0 N.m (8.0 ~ 10.0 kgf.m, 57.8 ~ 72.3 lb-ft)

4.
Remove the tie rod end ball joint (A) from the knuckle.
(1)
Remove the split pin (B).
(2)
Remove the castle nut (C).
Tightening torque:
34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.5 lb-ft)

5.
Loosen the mount bolt and then remove the wheel speed sensor (B) from knuckle (A).
Tightening torque:
6.8 ~ 10.7 N.m (0.7 ~ 1.1 kgf.m, 5.0 ~ 7.9 lb-ft)

6.
Remove driveshaft coking nut (A) from the front hub under applying the break.
Tightening torque:
196.1 ~ 254.9 N.m (20.0 ~ 26.0 kgf.m, 144.6 ~ 188.0 lb-ft)

•
The rear hub lock nut should be replaced with new ones.
•
After installation lock nut, stake the lock nut using a chisel and hammer as shown in the illustration below.

7.
Loosen the front brake disc mount screw and then remove the front brake disc (A).
Tightening torque:
4.9 ~ 5.8 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)

8.
Remove the lower arm (A) from the knuckle.
Tightening torque:
98.0 ~ 117.6 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.7 lb-ft)

9.
Disconnect the driveshaft (A) from the front hub assembly.
10.
Remove the driveshaft cover (A).
11.
Loosen the mounting bolts and then remove the inner shaft (A) & driveshaft assembly (B).
12.
Disconnect the driveshaft (A) from inner shaft (B).
13.
Install in the reverse order of removal.
•
Use a pry bar (A) being careful not to damage the transaxle and joint.
•
Do not insert the pry bar (A) too deep, as this may cause damage to the oil seal.
•
Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting in a torn boot or a damaged bearing.
•
Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
•
Support the driveshaft properly.
•
Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
14.
Check the alignment. (Refer to SSgroup 'Tires/Wheels - alingment')

Inspection

1.
Check the driveshaft boots for damage and deterioration.
2.
Check the driveshaft spline for wear or damage.
3.
Check that there is no water or foreign material in the joint.
4.
Check the spider assembly for roller rotation, wear or corrosion.
5.
Check the groove inside the joint case for wear or corrosion.
6.
Check the dynamic damper for damage or cracks.

Disassembly

•
Do not disassemble the BJ assembly.
•
Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.
•
The boot band should be replaced with a new one.
1.
Remove the circlip (B) from the driveshaft spline (A).
2.
Remove both boot bands from the transaxle side joint(TJ) case.
3.
Pull out the boot from transaxle side joint case (B).
4.
While dividing joint(TJ) boot (A) of the transaxle side, wipe the grease in TJ case (B) and collect them respectively.

Make alignment marks on spider roller assembly (A), joint case (B), and shaft spline (C) to aid reassembly.

5.
Remove the snap ring (A) and spider roller assembly from the shaft.
6.
Remove the spider assembly (B) from the driveshaft (A) using the special tool (09495-33000).
7.
Clean the spider assembly.
8.
Remove the boot (A) of the transaxle side joint(TJ).
For reusing the boot (A), wrap tape (B) around the driveshaft splines (C) to protect the boot (A).

9.
Using a plier or flat-tipped (-) screwdriver, remove the both side of clamp (B) of the dynamic damper (A).
10.
Fix the driveshaft (A) with a vice (B) as illustrated.
11.
Apply soap powder on the shaft to prevent being damaged between the shaft spline and the dynamic damper when the dynamic damper is removed.
12.
Saperate the dynamic damper (A) from the shaft (B) carefully.

Reassembly

1.
Wrap tape around the driveshaft spline(TJ) to prevent damage to the boots.
2.
Apply grease to the joint boot on the side of the wheel and install the boot.
3.
Install the clamp.
4.
To install the dynamic damper (A), keep the shaft in a straight line and assemble the dynamic damper with the bands (B).
5.
Assemble the transaxle side joint boot and bands.
6.
Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and snap ring (B) on the driveshaft splines (C).
7.
Add specified grease to the joint boot as much as it was wiped away at inspection.
8.
Install the both boot band.

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